Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 523
1 - Clutch Housing
2 - Oil Deflector Ring
3 - Dished Washer
❑ Removing. Refer to
❑ Installing. Refer to
4 - Outer Race/Tapered Roller
Bearing
❑ Removing. Refer to
❑ Installing. Refer to
5 - Inner Race / Tapered Roller
Bearing
❑ Removing. Refer to
❑ Installing. Refer to
⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing”“ ,
6 - Output Shaft
❑ For 1st through 4th gear
❑ There are different versions. Refer to
⇒ Fig. ““Differentiation of Output Shafts”“ , page 168
❑ Allocate according to the transmission code letters. Refer to the Parts Catalog.
❑ Adjusting. Refer to
⇒ “2.3 Output Shaft, Adjusting”, page 187
7 - Needle Bearing
❑ For 2nd gear
8 - 2nd Gear Wheel
9 - 2nd Gear Inner Race
❑ Replace if there are wear grooves
❑ Installed position. Refer to
⇒ Fig. ““Installing 2nd Gear Outer Race, Inner Race and Synchronizer Ring”“ , page 177
10 - 2nd Gear Outer Race
❑ Check the inner friction surface for wear. Refer to
⇒ Fig. ““Checking the Inner Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer
Ring, and the 3rd Gear Outer Ring ”“ , page 176
❑ Check the outer friction surface for wear. Refer to
⇒ Fig. ““Checking the Outer Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer
❑ Installed position. Refer to
⇒ Fig. ““Installing 2nd Gear Outer Race, Inner Race and Synchronizer Ring”“ , page 177
.
11 - 2nd Gear Synchronizer Ring
❑ Check the inner running surface for grooves and radial wear
❑ Installed position. Refer to
⇒ Fig. ““Installing 2nd Gear Outer Race, Inner Race and Synchronizer Ring”“ , page 177
.
12 - Locking Collar with Synchronizer Hub for 1st and 2nd Gears
❑ After removing the circlip, remove with the 2nd gear wheel. Refer to
⇒ Fig. ““Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear”“ , page 176
.
❑ Disassembling. Refer to
⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd
❑ Assembling the locking collar/synchronizer hub. Refer to
⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd
⇒ Fig. ““Assembling: Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears”“ , page 177
❑ Installed position. Refer to
⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears”“ , page 177
.
❑ Installing. Refer to
⇒ Fig. ““Warming and Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears.”“ ,
13 - Locking Ring
14 - 1st Gear Synchronizer Ring
❑ Check the inner running surface for grooves and radial wear
❑ Installed position. Refer to
⇒ Fig. ““Installing the Synchronizer Ring for 1st Gear Outer Race and Inner Race”“ , page 178
15 - 1st Gear Outer Race
❑ Check the inner friction surface for wear. Refer to
⇒ Fig. ““Checking the Inner Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer
Ring, and the 3rd Gear Outer Ring ”“ , page 176
❑ Check the outer friction surface for wear. Refer to
⇒ Fig. ““Checking the Outer Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer
Ring, and the 3rd Gear Outer Ring”“ , page 176
❑ Installed position. Refer to
⇒ Fig. ““Installing the Synchronizer Ring for 1st Gear Outer Race and Inner Race”“ , page 178
16 - 1st Gear Inner Race
❑ Replace if there are wear grooves
❑ Installed position. Refer to
⇒ Fig. ““Installing the Synchronizer Ring for 1st Gear Outer Race and Inner Race”“ , page 178
17 - Needle Bearing
❑ For 1st gear
18 - 1st Gear Wheel
❑ Mount on the output shaft. Refer to
⇒ Fig. ““Install 1st Gear Wheel with Needle Roller Bearing”“ , page 178
19 - Thrust Washer
❑ Quantity: 2
❑ For 1st and 4th gears
❑ The tab on the thrust washer must fit into the hole in the output shaft.
❑ Not installed on transmissions with reinforcement measures
20 - Retaining Ring
❑ Holds the thrust washers for the 1st and 4th gear in place on the output shaft
❑ Not installed on transmissions with reinforcement measures
21 - Collar Bushing
❑ For the 4th gear needle bearing
❑ Only installed on transmissions with reinforcement measures. Refer to
⇒ Fig. ““Reinforcement Measures on Manual Transmission 0FB near 4th Gear Wheel”“ , page 167
❑ Allocate according to the transmission code letters. Refer to the Parts Catalog.
22 - Needle Bearing
❑ For 4th gear
❑ There are different versions. Refer to
⇒ Fig. ““Variations of the Needle Bearing and Gear Wheels for 4th Gear”“ , page 168
❑ Allocate according to the transmission code letters. Refer to the Parts Catalog.
23 - 4th Gear Wheel
❑ There are different versions. Refer to
⇒ Fig. ““Variations of the Needle Bearing and Gear Wheels for 4th Gear”“ , page 168
❑ Allocate according to the transmission code letters. Refer to the Parts Catalog.
24 - 4th Gear Synchronizer Ring
❑ Brass or steel
❑ Checking for wear. Refer to
⇒ Fig. ““Checking the 4th Gear Synchronizer Ring for Wear”“ , page 179
25 - Locking Collar with Synchronizer Hub for 3rd and 4th Gears
❑ After removing the locking ring, remove the 4th gear wheel. Refer to
⇒ Fig. ““Removing the 3rd and 4th Gear Synchronizer Hub/Locking Collar with the 4th Gear Wheel”“ ,
❑ Disassembling. Refer to
⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd
.
❑ Assembling the locking collar/synchronizer hub. Refer to
⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd
and
⇒ Fig. ““Assembling: Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears”“ , page 177
❑ Installed position: locking collar/synchronizer hub. Refer to
⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears”“ , page 180
❑ Installing. Refer to
26 - Locking Ring
27 - 3rd Gear Synchronizer Ring
❑ Check the inner running surface for grooves and radial wear
❑ Installed position. Refer to
⇒ Fig. ““Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner Ring”“ , page 180
.
28 - 3rd Gear Outer Race
❑ Check the inner friction surface for wear. Refer to
⇒ Fig. ““Checking the Inner Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer
Ring, and the 3rd Gear Outer Ring ”“ , page 176
❑ Check the outer friction surface for wear. Refer to
⇒ Fig. ““Checking the Outer Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer
Ring, and the 3rd Gear Outer Ring”“ , page 176
❑ Installed position. Refer to
⇒ Fig. ““Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner Ring”“ , page 180
.
29 - 3rd Gear Inner Race
❑ Replace if there are wear grooves
❑ Installed position. Refer to
⇒ Fig. ““Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner Ring”“ , page 180
.
30 - Needle Bearing
❑ For 3rd gear
31 - 3rd Gear Wheel
❑ Mount on the output shaft. Refer to
⇒ Fig. ““Installing the 3rd Gear Wheel with Needle Bearing”“ , page 181
32 - Inner Race / Tapered Roller Bearing
❑ Removing. Refer to
⇒ Fig. ““Remove the Inner Race/Tapered Roller Bearing on the side of the Transmission Housing”“ ,
❑ Installing. Refer to
33 - Locking Ring
❑ Determine again when replacing inner race/tapered roller bearing and output shaft. Refer to
⇒ Fig. ““Selecting the Locking Ring”“ , page 174
34 - Outer Race/Tapered Roller Bearing
❑ Removing. Refer to
⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing”“ ,
❑ Installing. Refer to
⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing”“ , page 175
35 - Shim
❑ Selecting thickness. Refer to
⇒ “2.3 Output Shaft, Adjusting”, page 187
.
36 - Transmission Housing
Reinforcement Measures on Manual Transmission 0FB near 4th
Gear Wheel
The following components are affected.
1 - Output Shaft
Characteristics. Refer to
⇒ Fig. ““Differentiation of Output Shafts”“ , page 168
2 - Collar Bushing
Characteristics. Refer to
⇒ Fig. ““Variations of the Needle Bearing and Gear Wheels for 4th
3 - Needle Bearing for 4th Gear
Characteristics. Refer to
⇒ Fig. ““Variations of the Needle Bearing and Gear Wheels for 4th
4 - 4th Gear Wheel
Characteristics. Refer to
⇒ Fig. ““Variations of the Needle Bearing and Gear Wheels for 4th
Note
♦
Never mix parts for reinforced 4th gear transmissions and 4th
gear transmissions without reinforcement. Refer to the Parts
Catalog.
♦
To remove and install modified components, follow instruc‐
tions in repair manual. Refer to
⇒ “2.2.1 Output Shaft, Disassembling and Assembling, 1st to
.
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